Exploring A New Frontier: Desktop EDM Is Coming

July 5, 2023 by Tom Nardi 27 Comments

To say that desktop 3D printing had a transformative effect on our community would be something of an understatement. In just a decade or so, we went from creaky printers that could barely extrude a proper cube to reliable workhorses that don’t cost much more than a decent cordless drill. It’s gotten to the point that it’s almost surprising to see a project grace these pages that doesn’t include 3D printed components in some capacity.

There’s just one problem — everything that comes out of them is plastic. Oh sure, some plastics are stronger than others…but they’re still plastic. Fine for plenty of tasks, but certainly not all. The true revolution for makers and hackers would be a machine that’s as small, convenient, and as easy to use as a desktop 3D printer, but capable of producing metal parts.

If Cooper Zurad has his way such a dream machine might be landing on workbenches in as little as a month, thanks in part to the fact that its built upon the bones of a desktop 3D printer. His open source Powercore device allows nearly any 3D printer to smoothly cut through solid metal using a technique known as electrical discharge machining (EDM). So who better to helm this week’s Desktop EDM Hack Chat?

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3D Printing Food Hack Chat

July 3, 2023 by Dan Maloney 1 Comment

Join us on Wednesday, July 5 at noon Pacific for the 3D Printing Food Hack Chat with Ellie Weinstein!

In the right hands, food goes beyond mere sustenance and becomes a work of art. We’ve all seen examples — the carefully crafted blends of flavors, the quality ingredients expertly cooked, the artful platings that make a dramatic presentation at the table. But where the artistry really seems to take off is with desserts, which pastry chefs and confectioners can take to the next level with edible sculptures of chocolate and other sweets that can tower dramatically over the table.

That’s all well and good for the haute cuisine set, but what about the rest of us? We can’t all have the talent and drive needed to produce edible art, so perhaps we can leverage technology to help us out. That’s just one of the rationales behind food 3D printing, which is what we’ll be exploring with Ellie Weinstein. She’s the CEO of Cocoa Press, where they’re bringing chocolate 3D printing to the mainstream. It’s not as easy as you might think — there are plenty of nuances and engineering challenges when you’re trying to print chocolate or any other kind of food. Make sure you stop by and check it out; it’s sure to be a treat.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, July 5 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

Democratizing Space, One Picosatellite At A Time

June 28, 2023 by Tom Nardi 50 Comments

There was a time when putting an object into low Earth orbit was the absolute pinnacle of human achievement. It was such an outrageously expensive and complex undertaking that only a world superpower was capable of it, and even then, success wasn’t guaranteed. As the unforgiving physics involved are a constant, and the number of entities that could build space-capable vehicles remained low, this situation remained largely the same for the remainder of the 20th century.

But over the last couple of decades, the needle has finally started to move. Of course spaceflight is still just as unforgiving today as it was when Sputnik first streaked through the sky in 1957, but the vast technical improvements that have been made since then means space is increasingly becoming a public resource.

Thanks to increased commercial competition, putting a payload into orbit now costs a fraction of what it did even ten years ago, while at the same time, the general miniaturization of electronic components has dramatically changed what can be accomplished in even a meager amount of mass. The end result are launches that don’t just carry one or two large satellites into orbit, but dozens of small ones simultaneously.

To find out more about this brave new world of space exploration, we invited Nathaniel Evry, Chief Research Officer at Quub, to host last week’s DIY Picosatellites Hack Chat.

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Desktop EDM Hack Chat

June 26, 2023 by Dan Maloney 10 Comments

Join us on Wednesday, June 28 at noon Pacific for the Desktop EDM Hack Chat with Cooper Zurad!

Whether you know it or not, chances are pretty good you’ve run into the results of electrical discharge machining at some point. EDM is the go-to machining method for so many applications, from making complex injection molding tooling to putting impossibly small holes into hardened steel, EDM gets the jobs that make traditional machining techniques weep.

At its heart, EDM is really simple; it’s just making sparks to selectively erode metal. In practice, though, it’s way more complicated than that. There’s the CNC aspect to control the cutting tool, the dielectric to cool things and flush away the swarf, and the precision control of the electric discharge. It’s all just complicated and expensive enough that it’s hard to find anyone doing EDM on the hobbyist level.

Hard, but not impossible. Desktop EDM is doable, and to help us understand the challenges involved we’ve invited Cooper Zurad to the Hack Chat. Cooper has quite a bit of experience with the related and somewhat less energetic ECM, or electrochemical machining, and is now turning the knowledge gained there to desktop EDM. Make sure to join us with your questions about machining with electricity.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, June 28 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

[Featured image by Qw5646, CC BY-SA 3.0]

DIY Picosatellites Hack Chat

June 19, 2023 by Dan Maloney 10 Comments

Join us on Wednesday, June 21 at noon Pacific for the DIY Picosatellites Hack Chat with Nathaniel Evry!

Building a satellite and putting it in orbit was until very recently something only a nation had the resources to accomplish, and even then only a select few. Oh sure, there were a few amateur satellites that somehow managed to get built on a shoestring budget and hitch a ride into space, and while their stories are deservedly the stuff of legends, satellite construction took a very long time to be democratized.

Fast forward a half-dozen or so decades, and things have changed dramatically. Satellite launches are still complex affairs — it’s still rocket science, after all — but the advent of the CubeSat format and the increased tempo of launches, both national and commercial, has pushed the barriers to private, low-budget launches way, way down. So much so, in fact, that the phrase “space startup” is no longer something to snicker about.

One such group of space entrepreneurs is Quub, Inc., a small company in Lancaster, Pennsylvania which is looking to build and fly a constellation of microsatellites to monitor Earth’s environment in real-time. They’re building sats and signing launch deals using consumer-grade technology and modularized construction, and we’re lucky enough to have Nathaniel Evry, their Chief Research Officer, stop by the Hack Chat. If you’ve ever wondered what it takes to build hardware that can stand the rigors of launch and then perform a task in space, you’ll want to tune in for this one.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, June 21 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter. Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.

Passionate Hams Make Their Mark On The Hack Chat

June 12, 2023 by Tom Nardi 63 Comments

Let’s be honest — there are some not very pleasant stereotypes associated with amateur radio, at least if you ask outsiders. Hams are often thought of as being in two camps: old guys who can’t figure out modern technology or conspiracy theorists who think their knowledge of radio will give them an edge after the world becomes a post-apocalyptic hellscape. We’ll leave it to you to decide which is the worse brush to be painted with.

As is often the case, the best way to fight such ignorance is with education and outreach. Events like our weekly Hack Chat are a perfect platform for that, as it allows the curious to ask questions and get answers directly from subject matter experts. This is precisely why we invited Mark Hughes and Beau Ambur to helm last week’s Chat. The fact that they’re both relatively recent licensees makes them uniquely qualified to shed some light on what it’s like to become part of the ham radio community in the 21st century. As an added bonus, they’re both sharp and articulate technologists — about as far as you can get from the mental image of the doddering old granddad who prefers the simplicity of the Morse key to those newfangled smarty-phones.

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Getting Started In Ham Hack Chat

June 5, 2023 by Dan Maloney 41 Comments

Join us on Wednesday, June 7 at noon Pacific for the Getting Started in Ham Hack Chat with Mark Hughes and Beau Ambur!

If you were to scratch any random hacker from the last 100 years, chances are pretty good you’d find an amateur radio operator just beneath the surface. Radio is the first and foremost discipline where hacking was not only welcomed, but required. If you wanted to get on the air, you sat down with some coils of wire, a few random parts — as often as not themselves homemade — and a piece of an old breadboard, and you got to work. Build it yourself or do without, and when it broke down or you wanted to change bands or add features, that was all on you too.

Like everything else, amateur radio has changed dramatically over the decades, and rolling your own radio isn’t exactly a prerequisite for entry into the ham radio club anymore. Cheap but capable handheld radios are available for a pittance, better quality radios are well within most people’s budget, and commercially available antennas have reduced the need to dabble in that particular black art. The barrier to entry for amateur radio has never been lower; you don’t even have to learn Morse anymore! So why haven’t you gotten a license?

Whatever your reason for putting off joining the club of licensed amateur radio operators, we’re going to do our best to change your mind. And to help us do that, we’ve asked Mark Hughes (KE6WOB) and Beau Ambur (K6EAU) to swing by the Chat and share their experiences with getting on the air. Both are relatively recent licensees, and they’ll do their best to answer your questions about getting on the air for the first time, to get on your way to building that first radio.

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, June 7 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.